For background, I have a 30k mile 07 Saturn Sky 2.4 with an RPM turbo kit on it, and have been going back and forth with Martin at RPM to dial in my tune. I had a performance engine builder do my turbo install, but seeing as I currently work in the automotive industry and have dug around trying to find the source of the problem, I am pretty familiar with the system as a whole now.
I have my theories as to what the issue could be (exhaust leak, intake leak, faulty MAF connector). I've already tried the following and they haven't seemed to cure my cars problems:
1. tightened down the down pipe to exhaust at the downstream o2 sensor to crush the donut gasket better
2. Tuned the car to command a rich AFR so I know that there's not a true lean condition
3. listened all over the engine bay for leaks and can't hear anything.
4. checked the vacuum on my gauge (20 in/Hg at idle)
5. checked the intake system with a smoke machine and didn't see any smoke coming out and checked it with a propane torch while the car was running to insure that I don't have a vacuum leak (there could be one, but to the best of my ability, there isn't).
6. checked the evap purge solenoid (no leaks in the solenoid or the vacuum line to the manifold)
7. purchased a new OEM MAF and made sure the seal was air tight.
8. Pulled the injectors and greased the o-rings on the collars and on the injectors They had small dark spots around the injector seat, so I cleaned them up but took pictures if anyone wants to see.)
9. pulled the 2 bar MAP sensor and greased that o-ring as well.
I have noticed that when I unplug the MAF, the car actually seems to want to start up quickly and run smoothly, and I don't get a p0171 lean code or corrections to my fuel trims and I don't get a random misfire code. I don't have a wideband on the car yet, but I'm planning on adding that this week. I've uploaded the datalogs (with descriptive names) and the tune file that I'm currently running I'd love for someone else to look at them and see if they can spot an issue that might point me in a good direction. I'm getting a little frustrated with no more progress made on what could possibly be causing the car to think it's running ultra lean on idle and think it's running rich under boost.
With the MAF sensor plugged in, the spark* is constantly jittering around and making the car stutter, and whenever I come to a stop, the rpms drop to 400 making the car seem like it wants to die before jumping back up and idling around 800
I made the mistake of reading through the Terminator Tune thread where the dude ragged on his car and blew his engine and hopefully that doesn't become me I drive my car very carefully while constantly monitoring temps and KR, and I haven't gone WOT or even got over 5psi yet from fear of causing some damage.
01 - no MAF sensor.hpl
06 - new MAF - 10 min run.hpl
Leeman_Stevens RPM rev9.hpt
Leeman_Stevens_2007_Sky_StockTune.hpt